Phenol-hcho-urea resin for a sizing composition, a process for its perparation and the sizing composition obtained

ABSTRACT

A condensation product of phenol, formaldehyde and urea condensed in the presence of a basic catalyst, said condensation product being a liquid and having a free phenol content below 0.5%, a free formaldehyde content below 3%, expressed by weight based on the total weight of liquid, and a dilutability, measured at 20° C., of at least equal to 1000%.

BACKGROUND OF THE INvENTION

1. Field of the Invention

The present invention relates to the manufacture of mineral fiberproducts, and in particular insulating products, in the form of felts orsheets of fibers. The manufacturing process employed includes thedeposition on the fibers, by spraying or some other means, of a sizebased on phenoplasts or aminoplasts for bonding the fibers.

The present invention relates to a new condensation product or resinwhich is to enter into a sizing composition of the type described above,a process for the preparation of said product and a sizing compositioncontaining said product.

2. Description of the Prior Art

The term "resin" as used in the context of the present invention meansthe product resulting from the presence of a catalyst before any curingtakes place in an oven.

The properties desired of sizing compositions depend to a large extenton the characteristics of the basic resin. A good sizing compositionshould above all be easily sprayed and capable of covering and bondingthe fibers, and at the same time it should cause little pollution.

For this purpose, the basic resin should have good long term stabilityand a high degree of dilutability with water. Since the concept ofdilutability is particularly important, it will be defined for thepurposes of the present invention as follows: The water dilutability ofa resin solution is the volume of de-ionized water which can be added ata given temperature to one unit volume of this solution withoutproducing any permanent perturbation.

It is also necessary that the basic resin should be as free as possiblefrom any unconverted starting materials. The risk of atmosphericpollution is in fact mainly due to the presence of volatile monomers.These consist, for example, of the starting materials required forproducing the resin, e.g. formaldehyde and phenol, which have been leftunconverted by the reaction or regenerated in the course of sizing ofthe fibres or subsequently.

In order, therefore, that the sizes obtained may be as free as possiblefrom substances causing pollution, in particular free phenol and freeformaldehyde, the basic resin should contain as little residues ofstarting material as possible while preserving its useful qualities.

In the past, the first resins proposed were obtained from phenol andformaldehyde in a molar ratio of F/P below 2.5, urea then beingintroduced only together with the other sizing additives after formationand storage of the resin in order to bind the free formaldehyde. Becauseof the low molar ratio of formaldehyde to phenol (F/P), it is notpossible to obtain a free phneol content below 1.5% of the total weightof the resin solution, and the free formaldehyde content also amounts toat least 6%. Moreover, even the introduction of a large quantity of ureainto the size in order to reduce this free formaldehyde content doea notenable the formaldehyde content to be controlled.

Various methods aimed at reducing the volatile free monomer contentpresent in a sizing composition based on a phenoplast resin have beenproposed. The principle of these methods is based on the idea ofincreasing the initial molar ratio of formaldehyde to phenol (F/P) inorder to lower the uncombined and consequently free phenol content andat the same time bind the free formaldehyde present in excess by meansof nitrogen compounds, in particular urea.

Various formulations of basic resins obtained from a molar ratio offormaldehyde to phenol in the range of from 2.7 to 4.2 in the presenceof a basic catalyst have been envisaged. For example in U.S. Pat. No.3,616,179, a condensation product of phenol, formaldehyde and urea hasbeen proposed. The product obtained has a satisfactory capacity fordilution but, because of method of preparation employed, it is notpossible to achieve a very low uncombined free phenol content whilepreserving the satisfactory capacity for dilution. The urea isintroduced into the reactor where the reaction of phenol withformaldehyde takes place at a temperature suitable for this reaction,which is of the order of 70° C. In order to avoid excessively rapidpolymerization, which would entail the risk of problems of prematuregelling which would prevent spraying of the sizes, the reaction ofphenol with formaldehyde is blocked before most of the phenol hasreacted.

In another technique as disclosed in U.S. Pat. Nos. 3,684,467 and4,014,726, proposals have been advanced to prepare a condensationproduct of phenol, formaldehyde, dextrine or dicyandiamide and urea. Toobtain this product, a first type of formaldehyde binding agent(dextrine or dicyandiamide) is introduced and reacted at a temperaturecorresponding to the reaction temperature of phenol and formaldehyde,and the urea is introduced and reacts as soon as cooling of the reactionmedium has started.

Apart from the disadvantages already mentioned above regarding theincomplete conversion of phenol, this solution requires the presence oftwo formaldehyde binding agents. In addition, the temperature cycles arevery long and require a length of time corresponding to more than oneshift.

None of the solutions proposed in the prior art have ever provided aresin containing only a small proportion of free phenol and freeformaldehyde in order to limit the problems of pollution, whilepreserving the characteristic properties of a resin suitable forentering into a sizing composition and in particular a high capacity fordilution and high stability. A need therefore continues to exist for asizing composition which achieves these objectives.

SUMMARY OF THE lNVENTION

One object of the present invention is to provide a sizing compositionwhich does not result in significant environmental pollution.

Another object of the present invention is to provide a sizingcomposition which has a high capacity for dilution.

A further object of the invention is to provide a process for thepreparation of a resin for a sizing composition, which resin exhibitsimproved use properties and enables a more effective sizing to beobtained, the process of preparation of the resin according to theinvention advantageously comprising simplified operating means such as ashorter reaction cycle and the use of only one type of monomer forbinding the excess formaldehyde.

Briefly, these objects and other objects of the present invention ashereinafter will become more readily apparent can be obtained by a resinwhich is the condensation product of phenol, formaldehyde and urea inthe presence of a basic catalyst. The condensation product is a liquidhaving a free phenol content below 0.5%, a free formaldehyde contentbelow 3% of the total weight of the reactive liquid, and a dilutability,as measured at 20° C., of at least 1000%. The free phenol content ispreferably below 0.4%, the free formaldehyde content preferably below0.3% and the dilutability preferably at least 2000%. An additionalcharacteristic of the resin is that it has a dry extract content above40%

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The resin of the present invention is prepared by reacting phenol andformaldehyde together in the presence of a basic catalyst at atemperature in the range of from 60° to 75° C., preferably at about 70°C., the molar ratio F/P being between 3 and 6, until the conversion rateof phenol is above 98%, and the reaction mixture then begins to becooled and urea is introduced in such a quantity that the molar ratioU/P will be in the range of: ##EQU1##

At a temperature below 60° C., the reaction is too slow for industrialapplication, while at a temperature above 75° C. the free phenol contentis too high.

The quantity of urea present in the resin depends, in fact, oncontradictory requirements. In order to be certain to fix as large aquantity as possible of the free formaldehyde, it would be advantageousto introduce urea into the reaction medium in a large excess over thestoichiometric amount. However, urea introduced in too great a quantityabove a certain level of the U/P molar ratio does not serve to bind anymore free formaldehyde.

According to one characteristic of the present invention, theformaldehyde and phenol are reacted in the presence of a quantity ofcatalyst corresponding to 12 to 20% and preferably about 14% of hydroxylion equivalents expressed in weight of the initial phenol. The largequantity of catalyst favors the reaction of phenol with formaldehyde andalso reduces the time required for maintaining the temperature withoutaffecting the use properties of the final product, in particular itscapacity for dilution. The quantity of catalyst used should, however,not be too great in order not to bring about too violent a reaction orthe formation of undesirable products, in particular insoluble products.

The catalyst employed may be any alkali metal or alkaline earth metalhydroxide. Suitable catalysts include lime, barium hydroxide or one ofits hydrates, and the like. However, potassium and sodium hydroxide arepreferred, particularly sodium hydroxide, said alkali metal hydroxidesbeing used in quantities of 5 to 8.5% by weight of the initial phenol.

In a preferred embodiment of the invention, urea is introduced into thereaction medium as soon as cooling begins. In order that the urea andformaldehyde may react under the best possible conditions, it isadvantageous to cool the reaction mixture at a rate on the order of 1°C. per minute until a temperature of ca.35° C. is reached. The urea isintroduced at a very uniform rate during this stage of cooling,preferably over a period amounting to at least half the time requiredfor cooling the reactor and the reaction mixture.

The preparation of the resin is carried out-in a temperature cycle whichfalls into three phases: a heating phase, a phase during which thetemperature is maintained, and a cooling phase. Because of the nature ofthe present process, the cycle is very rapid, which is advantageous bothfrom an economical and a technological point of view compared with thecycles described in the prior art. In particular the total duration ofthe cycle from charging of the reactor to the point at which the resinis obtained does not exceed 7 hours when carried out on an industrialscale, the time during which the temperature is kept constant beinglimited to only about 90 minutes.

According to one variation of the process of the invention, a stage ofneutralization to a pH of about 7 to 7.5 may be added.

The sizing composition of the present invention can be used for coatingmineral fibers, such as, for example glass fibres, by various methodsand in particular by spraying. The sizing composition contains the resinaccording to the invention, additional urea and sizing additives. Sizingadditives currently employed include silane and mineral oils, ammoniaand ammonium sulfate.

According to one characteristic of the sizing composition of the presentinvention, the proportions of condensation product measured in parts ofdry matter and of the additional urea are between 65 parts ofcondensation product to 35 parts of additional urea and 90 parts ofcondensation product to 10 parts of additional urea, preferably 80 partsto 20 parts.

Having generally described this invention, a further understanding canbe obtained by reference to certain specific examples which are providedherein for purpose of illustration only and are not intended to belimiting unless otherwise specified.

All the examples described below relate to the same method of operation,details of which will be given.

Unless otherwise indicated, the percentages are percentages by weightexpressed either in relation to the weight of phenol introduced or inrelation to the total weight of liquid present in the reaction medium.

The results obtained for the various examples are compared with regardto the following features concerning the resin:

appearance: clear, milky;

dilutability;

final free formaldehyde content in relation to the total weight ofliquid (F1_(f));

final free phenol content in relation to the total weight of liquid(P1_(f));

dry extract content. (To determine this, 2 g of resin in 10 cc of watercontained in a dish 50 mm in diameter and 20 mm in height are exposedfor 2 hours to 150° C. in a ventilated oven (dry extract %):

rate of phenol conversion. (This is the percentage of formaldehyde whichhas participated in the reactions with phenol and urea, based on 100% ofthe initial formaldehyde (Fc)); and

pH.

The resin is obtained as follows. Formaldehyde and phenol are introducedinto a reactor. The mixture is then either heated or cooled withmechanical stirring until a temperature slightly above the melting pointof phenol is obtained. Mechanical stirring is continued during the wholereaction cycle. The catalyst is introduced at a uniform rate and then,immediately after all the catalyst has been added, the temperature ofthe mixture is raised to a level suitable for optimum condensation andthe formation of a dilutable resin. This temperature is maintained untilthe conversation rate of phenol is above 98%.

Cooling of the reactor and the reaction medium is then begun and urea isintroduced. For storage, the resin is advantageously maintained underconditions of mild agitation at a temperature of approximately 16° C. Itmay be stored for at least 15 days.

To produce the sizing composition, additional urea and the usualadditives used in a sizing formulation are added.

All the data and results of the examples described are summarized inTables 1 and 2 below. They relate to the respective proportions of thevarious reactants at different stages of the process and to differentfeatures of the process (Table 1) and to the characteristics of theresins obtained (Table 2).

The data relating to the respective proportions of the various reactantsare molar ratios:

of formaldehyde to phenol (F/P);

of urea to initial phenol (U/P); and

of urea to free formaldehyde at the moment of introduction of urea (U/F₁at tU).

The other data given are the percentage of catalyst in proportion toinitial phenol (catalyst percent), the equivalent in hydroxyl ions(percent OH/P), the moment of introduction of urea (tU), and the freeformaldehyde content in relation to the reaction liquid at the moment ofintroduction of urea (F₁ at tU).

Examples 1 to 6 are in accordance within the scope of the presentinvention while Examples 7 to 11 are comparative reference exampleswhich are not within the scope of the present invention.

EXAMPLE 1

282.3 g of phenol (3 mol) are added to 852 g (10.5 mol) of a 37% aqueousformaldehyde solution in a 2 liter reactor equipped with stirrer,condenser, thermometer and inlet for reactants. The temperature isregulated by means of a water bath equipped with heating resistors andcontrolled manually or by a contact thermometer and a cooling system.

The preliminary mixture is raised to a temperature of 45° C. withstirring, and 33.88 g of a 50% aqueous sodium hydroxide solution (0.4235mol) and 6% by weight of initial phenol are then introduced at a uniformrate over a period of 30 minutes while the temperature is maintained at45° C.

The temperature is then raised at a uniform rate from 45° to 70° C. overa period of 30 minutes, and then maintained at 70° C.

Cooling is then begun and urea is introduced in granular form after thetemperature has been maintained at 70° C. for about 71 minutes. The freeformaldehyde content is then 8.4%.

The temperature is lowered uniformly from 70° to 50° C. in 20 minuteswhile 211.8 g (3.528 mol) of urea in granular form are introduced veryuniformly at an average rate of 10.59 g of urea per minute. Cooling iscontinued at the same rate down to 35° C.

The solution of resin obtained has a clear, pale yellow appearance. Theamount of phenol converted is 98.1%, the amount of formaldehydeconverted is 98.5%, and the dry extract is 44.3%. The dilutability ofthe resin is infinite.

EXAMPLE 2

The same apparatus as described for Example 1 is used. 254.6 g (2.7 mol)of phenol are added to 881.3 g (10.8 mol) of 37% formaldehyde. 30.49 gof 50% aqueous sodium hydroxide solution (0.381 mol) and 6% by weight ofthe initial phenol are added. The procedure is then conducted asdescribed in Example 1, but this time the temperature is maintained at70° C. for 90 minutes. The temperature of the reaction medium is thenlowered to 60° C. in 8 minutes so that a free formaldehyde content of10.4% is obtained. Lowering of the temperature is then continued at auniform rate from 60° to 35° C. in the course of 20 minutes, while 270.6g of granular urea are introduced at a uniform rate.

EXAMPLE 3

The conditions are analogous to those of Example 1 but the quantity ofcatalyst is modified, being increased to 8% of the sodium hydroxide or18.9% of equivalent in hydroxyl ions.

EXAMPLE 4

The U/P ratio is different from that used in Example 1 but still withinthe scope of the invention. Because of the reduced U/P ratio, the finalfree formaldehyde content is slightly raised.

EXAMPLE 5

This is another variation of the invention in which the U/P ratio isagain modified.

EXAMPLE 6

The F/P ratio and the quantity of catalyst are increased. Virtually 100%conversion of phenol and a very low free phenol content are achieved.After the reaction medium has been cooled to 35° C., it is neutralizedin about 90 minutes to a pH of 7.3 with the aid of a 15% solution ofsulfuric acid. This neutralization requires about 120g of acid.

All the resins obtained according to Examples 1 to 6 are stable for 15days.

COMPARISON EXAMPLES: EXAMPLE 7

Formaldehyde and phenol are introduced in the same F/p ratio of 3.5 asin Example 1 with the same quantity of catalyst, but no urea isintroduced into the reactor. The free formaldehyde content in the finalresin is raised to a level too high to enable the resin to be used in asizing composition.

EXAMPLE 8

The F/P ratio is reduced to a value below 3 and no urea is introduced.The resin obtained does not have any of the desired characteristics, inparticular the final free phenol content is 3.5% and the final freeformaldehyde content is 3.2%.

EXAMPLE 9 The F/P ratio is raised above that of Example 1 to a value of6 and no urea is introduced. The proportion of converted formaldehyde isfound to be insufficient, and consequently the free formaldehyde contentis excessive. EXAMPLE 10

Conditions analogous to those of Example 7 are sodium hydroxide beingreplaced by barium hydroxide introduced in an amount corresponding to16% by weight of phenol, i.e. 9.2% equivalents of hydroxyl ions. Thiscatalyst imparts to the resin a milky appearance, quite apart from theother unsatisfactory properties of Example 7.

EXAMPLE 11

The same conditions as those of Example 1 are employed. Introduction ofurea is begun when the temperature level of 70° C. required for thereaction of phenol with formaldehyde has been maintained for 78 minutes,and this temperature is then maintained for approximately a further 10minutes. The reaction mixture is then cooled to 35° C. while ureacontinues to be introduced for 10 minutes during cooling. The rate ofphenol conversion is substantially reduced and a very high level (0.8%)of final free phenol content is obtained.

After the resin has been prepared and then stored as required, the sizeis prepared by adding additional urea and sizing additives to the resin.The additional urea introduced into the size serves to bind theformaldehyde which is liable to be produced at the time of spraying ofthe size on the fibers or when the binder is cured at a high temperatureto bind the fibers.

A typical sizing composition includes the following additives:

(a) 1 to 3 parts of ammonium sulfate serving as catalyst duringsubsequent curing of the size after it has been sprayed on the fibers;

(b) 0.1 to 1 part of silane;

(c) 1 to 15 parts of mineral oils;

(d) 6 to 12 parts of ammonia in the form of a 20% solution used to delaypre-gelling of the size and hence preserve its dilutability.

The results obtained with examples of size produced from the resinsaccording to the present invention and with other examples produced fromresins which do not come within the scope of the invention aresummarized in Table 3.

Examples 12 to 14 are obtained from resins described in Examples 1, 4,and 5 above. Examples 15 and 16 correspond to resins described inExamples 7 and 10 above, which do not fall within the scope of thepresent invention.

All the examples obtained contain the same quantities of mineral oil,20% ammonia solution, silane and ammonium sulfate, i.e. 0.1% of silane,9.5% of mineral oil, 6% of ammonia, 3% of ammonium sulfate. Thepercentages given correspond to 100 parts of the total quantity of resinand additional urea.

In addition to the quantities of free formaldehyde (Fl%) and free phenol(Pl%) expressed by their dry matter content in the size, Table 3indicates the quantities of these elements, expressed in mg/Nm³, foundin the evacuated gases. German standards, in particular, require thetotal quantity of pollutants to be below 20 mg/Nm³. It is clear that theexamples of the invention conform to these standards. The dilutabilitymeasured after 3 days storage of the size is also satisfactory. Thequantity of binder fixed by glass fibers, for example, when sprayed witha sizing composition of the present invention is found to increasebecause of the reduction in free phenol and formaldehyde content of thesize.

                                      TABLE 1                                     __________________________________________________________________________                        Conversion                                                                    Rate. Form-                                                           OH.sup.- /P                                                                           aldehyde                                                                             tU: Moment and temperature                         Ex                                                                              F/P       Mol OH.sup.- /100                                                                     before urea                                                                          of starting the introduction                                                                Fl at                                                                              U/Fl                            No                                                                              Mol/Mol                                                                            Catalyst                                                                           Mol P   %      of urea       tU   at Tu                                                                              U/P                        __________________________________________________________________________    1 3.5  NaOH 14.1    69     At the end of maintenance                                                                   8.4  1.08 1.18                                                  of temperature at 70° C.                                               for 71 minutes                                     2 4    NaOH 14.1    52     In the course of cooling                                                                    10.4 0.71 1.06                                                  after 90 minutes at 70° C.                                             and 8 minutes cooling                                                         (70 to 60° C.)                              3 3.5  NaOH 18.9    70     At the end of temperature                                                                   8.0  1.08 1.18                                                  maintenance for 70 minutes                                                    at 70° C.                                   4 3.5  NaOH 14.1    69     At the end of temperature                                                                   8.3  0.725                                                                              0.78                                                  maintenance for 71 minutes                                                    at 70° C.                                   5 3.5  NaOH 14.6    69     At the end of temperature                                                                   8.3  0.363                                                                              0.39                                                  maintenance for 71 minutes                                                    at 70° C.                                   6 5    NaOH 18.9    44     At the end of temperature                                                                   13.8 0.725                                                                              1.22                                                  maintenance for 62 minutes                                                    at 70° C.                                   7 3.5  NaOH 14.5    69       --          --   --   0                          8 2.3  NaOH  8.5    79       --          --   --   0                          9 6    NaOH 14.1    43       --          --   --   0                          10                                                                              3.2  Ba(OH).sub.2                                                                       9.2     73       --          --   --   0                          11                                                                              3.2  Ba(OH).sub.2                                                                       9.2     71     In the course of mainten-                                                                   7.6  0.921                                                                              0.86                                                  ance of temperature for                                                       78 minutes at 70° C.                        __________________________________________________________________________

                                      TABLE 2                                     __________________________________________________________________________    RESULTS                                                                       Ex No.                                                                            Flf %                                                                             Plf %                                                                             Dry extract %                                                                         Appearance                                                                           Dilutability %                                                                        Pc %                                                                              Fc %                                                                              pH                                 __________________________________________________________________________    1   0.28                                                                              0.4 44.3    clear  2000    98.1                                                                              98.5                                   2   1.28                                                                              0.18                                                                              46.4    clear  2000    98.9                                                                              94                                     3   0.28                                                                              0.28                                                                              44.7    clear  2000    98.5                                                                              98.5                                   4   1.12                                                                              0.5 43      clear  2000    98  97                                     5   2.9 0.5 40      clear  2000    98  90                                     6   0.6 0.06                                                                              43.5    clear  2000    99.6                                                                              97  7.1 to 7.3                         7   7.35                                                                              0.41                                                                              34      clear  2000    98  70                                     8   3.2 3.5 41      clear  1000    88  85                                     9   16.3                                                                              0.13                                                                              35      milky  2000    99.4                                                                              43                                     10  6.6 1   37.6    milky  2000    95.8                                                                              73                                     11  0.35                                                                              0.8 46      milky  2000    95.8                                                                              97.0                                   __________________________________________________________________________

                                      TABLE 3                                     __________________________________________________________________________    Example of        Parts of                                                    corresponding                                                                              Parts of                                                                           additional    Pollution mg/Nm.sup.3                                                                   Dilutability                        Example                                                                            resin   resin                                                                              urea  Fl %                                                                              Pl %                                                                              Pl Fl Total                                                                             at 20° C.                    __________________________________________________________________________                                              %                                   12   1       80   20    1.6 0.4 6.8                                                                              5.6                                                                              12.4                                                                              1200                                13   4       80   20    1.15                                                                              0.6 7.6                                                                              5.5                                                                              13.1                                                                              700                                 14   5       80   20    3.7 0.5 5.8                                                                              7.4                                                                              13.2                                                                              300                                 15   7       55   45    11   0.25                                                                             6.1                                                                              14.2                                                                             20.3                                                                              600                                 16   10      55   45    10.4                                                                              1.7 23 13 36   0                                  __________________________________________________________________________

Having now fully described this invention, it will be apparent to one ofordinary skill in the art that many changes and modifications can bemade thereto without departing from the spirit or scope of the inventionas set forth herein.

What is claimed as new and desired to be secured by Letters Patent ofthe United States is:
 1. A process for the preparation of phenol,formaldehyde and urea condensate for use in a sizing composition formineral fibers wherein the phenol and formaldehyde are condensed in thepresence of a basic catalyst, the molar ratio F/P of formaldehyde tophenol being between 3 and 6, the basic catalyst being in an amount of12 to 20 moles of hydroxyl equivalent for 100 moles of initial phenol,the molar ratio U/P of urea to initial phenol being between ##EQU2##said condensate being a liquid and having a free phenol content below0.5%, a free formaldehyde content below 3% expressed by weight based onthe total weight of liquid, a water tolerance, measured at 20° C. of atleast equal to 1000%, a storage stability of at least 15 days and a dryextract content of at least equal to 40% consisting essentiallyof:heating together a preliminary mixture of phenol and formaldehyde ata temperature of about 45° C, raising the temperature up to between Ca60° C. and 75° C. and thereby reacting phenol and formaldehyde, afteraddition of a basic catalyst, and maintaining this temperature until thephenol conversion rate is above 98%, cooling the reaction medium andintroducing urea into the reaction medium.
 2. The process of claim 1,wherein said urea is introduced into the reaction medium as soon ascooling is begun.
 3. The process according to claim 2, wherein saidreaction medium is cooled to about 35° C. at a rate of the order of 1°C. per minute.
 4. The process according to claim: 2, wherein said ureais introduced into said reaction medium during a period equal to atleast half the time required to cool the reaction medium.
 5. the processof claim 1, wherein the duration of the temperature maintaining phasedoes not exceed 90 minutes.